Rotary filling apparatus and methods

ABSTRACT

Embodiments of the invention include apparatus for filling containers and related methods. In an embodiment, an apparatus includes a rotary turret assembly rotatably coupled to a filler frame. The rotary turret assembly can include a rotary base and a plurality of hollow columns mounted on the rotary base and arranged in a circle. A plurality of piston assemblies can be configured to move up and down within the hollow columns. Each piston assembly can include a piston body and a top hat assembly configured to releasably engage the top of the piston body. The piston body and the top hat assembly can release from one another when a release lever is engaged. Rotation of the rotary column group causes the cam contact members of the piston assemblies to move over a surface of a cam track causing vertical movement of the top hat assemblies. Other embodiments are included herein.

This application claims the benefit of U.S. Provisional Application No.62/025,317, filed Jul. 16, 2014, the content of which is hereinincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to apparatus for filling containers andrelated methods. More specifically, the present invention relates torotary filling apparatus and related methods.

BACKGROUND OF THE INVENTION

Containers of various sorts including bottles and cans and jars, etc.,are commonly filled with liquid type products in a production line by arotary type piston filling machines. In general, containers arrive on aconveyor line and are successively applied onto a turret in underlyingrelation with a revolving piston type filler. The filler has a pistonmoving in an upright cylinder, and the piston is reciprocated upwardlyand downwardly during revolving of the filler and turret so that theliquid product is drawn into the piston and is subsequently expelledfrom the piston into the container being filled. The amount of liquidproduct that is supplied into the container in the filling operation ismeasured by the magnitude of the piston movement in the cylinder, andthe size of the cylinder.

SUMMARY OF THE INVENTION

Embodiments of the invention include apparatus for filling containersand related methods. In an embodiment, the invention includes anapparatus for filling containers. The apparatus for filling containerscan include a filler frame, a rotary turret assembly, a filler plenumassembly, piston assemblies, a cam track, and a fluid supply group. Therotary turret assembly can include a rotary base and a plurality ofhollow columns. The plurality of hollow columns can be mounted on therotary base and arranged in a circle. The piston assemblies can move upand down within the plurality of hollow columns. The piston assembliescan further include a cam contact member. Rotation of the rotary turretassembly causes the cam contact member to move over a surface of the camtrack causing vertical movement of the piston assemblies relative to theplurality of hollow columns.

In various embodiments the cam track can include a first rising portion,a second rising portion, a first declining portion, a first flatportion, and a second declining portion. The first rising portion cancorrespond to a filling phase. The second rising portion can correspondto an overfilling phase. The first declining portion can correspond to apurging phase. The first flat portion can correspond to a hold phase.The second declining portion can correspond to a dispensing phase.

In an embodiment, the invention includes a method for fillingcontainers. The method for filling containers can include rotating arotary turret assembly, the rotary turret assembly comprising a rotarybase and a plurality of hollow columns mounted on the rotary base andarranged in a circle. The method can further include contacting a camcontact member against a cam track to cause piston assemblies disposedwithin the hollow columns to move up and down, drawing a food materialinto a bottom portion of the hollow columns when the piston assembliesmove up. The method can further include dispensing the food materialinto a container when the piston assemblies move down. In variousembodiments, the amount of the food material drawn into the hollowcolumn exceeds the amount ultimately dispensed into the container.

In an embodiment, the invention includes an apparatus for fillingcontainers. The apparatus for filling containers can include a fillerframe, a rotary turret assembly, a filler plenum assembly, pistonassemblies, a sensor, a lever actuator, a cam track, and a fluid supplygroup. The rotary turret assembly can include a rotary base and aplurality of hollow columns. The piston assemblies can move up and downwithin the plurality of hollow columns. The piston assemblies caninclude a piston body and a top hat assembly. The top hat assembly caninclude a cam contact member and a release lever.

The top hat assembly can be configured to releasably engage the top ofthe piston body. The release lever can allow the piston body and the tophat assembly to release from one another when the release lever isengaged. The sensor can detect the presence or absence of a container tobe filled. The lever actuator can be configured to contact the releaselever when the sensor indicates that a container to be filled is absent.Upon rotation of the rotary turret assembly, the cam contact membermoves over a surface of the cam track. However, because the cam contactmember is operably connected to the top hat assembly, rotation of therotary turret assembly only causes vertical movement of the piston bodyonly if the top hat assembly is connected to the piston body.

In an embodiment, the invention includes a method for fillingcontainers. The method for filling containers can include rotating arotary turret assembly, the rotary turret assembly comprising a rotarybase and a plurality of hollow columns mounted on the rotary base andarranged in a circle. The method can further include detecting whether acontainer to be filled is aligned with a particular hollow column andengaging a release lever that allows a top hat assembly to release froma piston body assembly if a container is not detected. The method canfurther include contacting a cam contact member operably connected tothe top hat assembly against a cam track to cause the top hat assemblydisposed within the hollow columns to move up and down. The method canfurther include drawing a food material into a bottom portion of thehollow columns when the piston body assemblies move up if the top hatassembly is not released from the piston body assembly. The method canalso include dispensing the food material into a container when thepiston body assemblies move down if the top hat assembly is not releasedfrom the piston body assembly.

In an embodiment, the invention includes an apparatus for fillingcontainers. The apparatus for filling containers can include a fillerframe, a rotary turret assembly, and a container conveyor system. Thecontainer conveyor system can be for supplying empty containers to therotary turret assembly and conveying filled containers away from therotary turret assembly. The container conveyor system can include aninfeed timing screw, a discharge timing screw, and a container elevationsystem. The container elevation system can be used to raise or lower atleast a portion of a track or rail so that the top height of thecontainers (such as cans) can be adjusted to be the correct height forthe rotary turret assembly. The container elevation system can include arail brace and a brace actuator. The brace actuator can be used to raiseor lower the height of the rail brace. A rail can be mounted on oradjacent to the rail brace. The containers to be filled can move alongthe rail. In some embodiments, the container elevation system can bedisposed under a portion of the infeed timing screw and the dischargetiming screw.

In an embodiment, the invention includes a method for fillingcontainers. The method for filling containers can include rotating arotary turret assembly, the rotary turret assembly comprising a rotarybase and a plurality of hollow columns mounted on the rotary base andarranged in a circle. The method can further include feeding containersto be filled into an infeed timing screw, passing the containers over acontainer rail, wherein the container rail is disposed adjacent theinfeed timing screw, adjusting the height of the containers andcontainer rail relative to the rotary turret.

In an embodiment, the invention includes an apparatus for fillingcontainers. The apparatus for filling containers can include a fillerframe, a rotary turret assembly, a filler plenum assembly, and a fluidsupply group. The filler plenum assembly can include a plenum. The fluidsupply group can include a liquid supply tank, a supply conduit, areclaim trough, a reclaim conduit, a pump, a plenum return conduit, anda pumped return conduit. The filler plenum assembly can be underlying aportion of the rotary turret assembly. The plenum can be in fluidcommunication with the plurality of hollow columns for a portion of eachrotation of the rotary turret assembly. The fluid supply group can be influid communication with the plenum. The supply conduit can providefluid communication between the liquid supply tank and the plenum. Thereclaim trough can be adjacent to the plenum. The reclaim conduit canprovide fluid communication between the reclaim trough and the pump. Theplenum return conduit can provide fluid communication between the plenumoutlet and the pump. The pumped return conduit can provide fluidcommunication between the pump and the liquid supply tank.

The components of the fluid supply group can provide for a closedcircuit fluid supply in that food materials can pass from the liquidsupply tank through the supply conduit to the plenum. Food materialsthat are not drawn into the hollow columns of the rotary turret assemblycan then pass out of the plenum through a plenum return conduit to apump. Also, in some embodiments, food materials recovered through areclaim trough can pass through a reclaim conduit to the pump. The pumpcan cause the food material to pass through a pumped return conduit backto the liquid supply tank either directly or indirectly. In someembodiments, this circuit can be operative even when the rotary turretis not rotating and filling containers such that food material can berecirculated and kept in proper condition for being filled intocontainers during temporary stoppages of the rotary turret.

In an embodiment, the invention includes a method for fillingcontainers. The method for filling containers can include rotating arotary turret assembly, the rotary turret assembly comprising a rotarybase and a plurality of hollow columns mounted on the rotary base andarranged in a circle. The method can further include delivering a foodproduct to a plenum disposed under a portion of the rotary turretassembly by conveying the food product from a liquid supply tank througha supply conduit to the plenum. The method can further include drawing afirst portion of the food product from the plenum into the hollowcolumns for dispensing into containers to be filled. The method canfurther include collecting a second portion of the food product disposedin the plenum and conveying the collected food product through an outletin the plenum and to a pump. The method can further include conveyingthe collected food product from the pump back to the liquid supply tank.

This summary is an overview of some of the teachings of the presentapplication and is not intended to be an exclusive or exhaustivetreatment of the present subject matter. Further details are found inthe detailed description and appended claims. Other aspects will beapparent to persons skilled in the art upon reading and understandingthe following detailed description and viewing the drawings that form apart thereof, each of which is not to be taken in a limiting sense. Thescope of the present invention is defined by the appended claims andtheir legal equivalents.

BRIEF DESCRIPTION OF THE FIGURES

Aspects herein may be more completely understood in connection with thefollowing drawings, in which:

FIG. 1 is a schematic top view of an apparatus for filling containers inaccordance with various embodiments herein.

FIG. 2 is a schematic side view of an apparatus for filling containersin accordance with various embodiments herein.

FIG. 3 is an exploded perspective view of an apparatus for fillingcontainers in accordance with various embodiments herein.

FIG. 4 is a partially exploded perspective view of a rotary turretassembly in accordance with various embodiments herein.

FIG. 5 is an exploded perspective view of a cam track assembly inaccordance with various embodiments herein.

FIG. 6 is a side view of a cam track assembly in accordance with variousembodiments herein.

FIG. 7 is a schematic view of a cam track and a rotary turret assemblyin accordance with various embodiments herein.

FIG. 8 is a schematic view of a cam track profile in accordance withvarious embodiments herein.

FIG. 9 is a schematic view of a piston assembly in accordance withvarious embodiments herein.

FIG. 10 is a piston assembly with the top hat assembly removed from thepiston body in accordance with various embodiments herein.

FIG. 11 is a cross-sectional schematic view of a portion of a pistonassembly in accordance with various embodiments herein.

FIG. 12 is a schematic top view of a container conveyor system inaccordance with various embodiments herein.

FIG. 13 is an exploded perspective view of a container conveyor systemin accordance with various embodiments herein.

FIG. 14 is a schematic perspective view of a container elevation systemin accordance with various embodiments herein.

FIG. 15 is a schematic view of elements of a fluid supply group inaccordance with various embodiments herein.

FIG. 16 is a schematic perspective view of a fluid supply group inaccordance with various embodiments herein.

FIG. 17 is an exploded schematic perspective view of a fluid supplygroup in accordance with various embodiments herein.

FIG. 18 is an exploded perspective view of a filler plenum assembly inaccordance with various embodiments herein.

FIG. 19 is a schematic view of elements of a fluid supply group inaccordance with various embodiments herein.

FIG. 20 is a flow chart of a method in accordance with variousembodiments herein.

FIG. 21 is a flow chart of a method in accordance with variousembodiments herein.

FIG. 22 is a flow chart of a method in accordance with variousembodiments herein.

FIG. 23 is a flow chart of a method in accordance with variousembodiments herein.

While the invention is susceptible to various modifications andalternative forms, specifics thereof have been shown by way of exampleand drawings, and will be described in detail. It should be understood,however, that the invention is not limited to the particular embodimentsdescribed. On the contrary, the intention is to cover modifications,equivalents, and alternatives falling within the spirit and scope of theinvention.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments of the present invention described herein are notintended to be exhaustive or to limit the invention to the precise formsdisclosed in the following detailed description. Rather, the embodimentsare chosen and described so that others skilled in the art canappreciate and understand the principles and practices of the presentinvention.

All publications and patents mentioned herein are hereby incorporated byreference. The publications and patents disclosed herein are providedsolely for their disclosure. Nothing herein is to be construed as anadmission that the inventors are not entitled to antedate anypublication and/or patent, including any publication and/or patent citedherein.

Embodiments herein include apparatus for filling containers that canachieve various operational advantages. By way of example, in someembodiments, the ability to fill a container with a food product that ispredominantly a liquid but also includes pieces of particulate materialsuch as pieces of meat, vegetables, garnish, or condiments and the like,can be achieved with increased consistency regarding the total amount ofthe food product filled, the relative amounts of the particular materialto the liquid portion, or both. In some embodiments, the efficiency ofthe filling operation in terms of how much product is actually depositedinto containers versus how much product is wasted can be improved. Insome embodiments, the ability to quickly reconfigure the apparatus toaccommodate containers of different heights is greatly improved. In someembodiments, the filling apparatus can use a closed loop product supplyapproach and in some cases can also recirculate the food product througha portion of the system when the filling operation temporarily ceases.This can lead to reduced waste by eliminating or reducing thecircumstances in which food product might otherwise have to be purgedfrom the system. It will be appreciated that not every embodimentincluded within the scope herein will achieve all of these operationaladvantages. However, many embodiments can achieve one or more theseoperational advantages.

Food products that can be filled into containers in accordance withvarious embodiments herein can include liquid food products or foodproducts that include a liquid portion such that they are flowable.Exemplary food products can include, but are not limited to, soups,stews, sauces, juices, beverages, and the like, and concentrates of anyof these. In some embodiments, the food product includes a substantialproportion of particulates having a diameter of greater than 1millimeter. In some embodiments, the food product includes at leastabout 1 wt. % of particulates having a diameter of greater than 1millimeter. In some embodiments, the food product includes at leastabout 2 wt. % of particulates having a diameter of greater than 1millimeter. In some embodiments, the food product includes at leastabout 5 wt. % of particulates having a diameter of greater than 1millimeter. In some embodiments, the food product includes at leastabout 10 wt. % of particulates having a diameter of greater than 1millimeter.

It will be appreciated that containers that are filled in accordancewith various embodiments can be of many different types. In someembodiments, the container can be formed of one or more metals,polymers, glasses, ceramics, cellulosic materials, or a combinationthereof. The containers can include, but are not limited to, cans, jars,bottles, pouches, and the like.

Referring now to FIG. 1, the apparatus for filling containers 102 caninclude a filler frame 104, a rotary turret assembly 106, pistonassemblies 112, and a fluid supply group 114. The rotary turret assembly106 includes a rotary base 108 and a plurality of hollow columns 110.The fluid supply group 114 includes a liquid supply tank 116 and asupply conduit 118. The apparatus for filling containers 102 can includea container conveyor system 120. The container conveyor system 120 caninclude an infeed timing screw 122 and a discharge timing screw 124.

In operation, at a high level, the container conveyor system providescontainers to the rotary turret assembly 106 for filling and thenconveys them away after they are filled. The rotary turret assembly 106pulls a food product or material for filling into the hollow columns 110and then dispenses the food product into containers as the rotary turretassembly 106 rotates. The fluid supply group 114 supplies the foodproduct to the rotary turret assembly 106.

Referring now to FIG. 2, the apparatus for filling containers 102 caninclude a filler frame 104, a rotary turret assembly 106, pistonassemblies 112, and a fluid supply group 114. The rotary turret assembly106 includes a rotary base 108 and a plurality of hollow columns 110.The piston assemblies 112 include a cam contact member 202. The camcontact member 202 can include a cam roller 204. FIG. 2 also shows arelease lever 206. The apparatus for filling containers 102 can includesensor 208. The apparatus for filling containers 102 can include leveractuator 210. Aspects of the release lever 206, sensor 208, and leveractuator 210 will be described in greater detail below. The fluid supplygroup 114 includes a liquid supply tank 116 and a supply conduit 118.The apparatus for filling containers 102 can include a containerconveyor system 120 including an infeed timing screw 122 and a dischargetiming screw 124.

Referring now to FIG. 3, the apparatus for filling containers 102 caninclude a filler frame 104, a rotary turret assembly 106, a fillerplenum assembly 302, piston assemblies 112, a cam track 306, and a fluidsupply group 114. The rotary turret assembly 106 includes a rotary base108 and a plurality of hollow columns 110. The filler plenum assembly302 includes a plenum 304. The piston assemblies 112 include a camcontact member 202. The fluid supply group 114 includes a liquid supplytank 116 and a supply conduit 118. The cam contact member 202 caninclude cam roller 204. The apparatus for filling containers 102 caninclude a container conveyor system 120 including an infeed timing screw122 and a discharge timing screw 124. The fluid supply group 114 caninclude a reclaim trough 308, a reclaim conduit 310, and a pump 312. Thefluid supply group 114 can also include a plenum return conduit 314 anda pumped return conduit 316.

Referring now to FIG. 4, the rotary turret assembly 106 includes arotary base 108 and a plurality of hollow columns 110. The cam contactmember 202 can include a cam roller 204. The apparatus for fillingcontainers 102 can include motor 402. It will be appreciated that themotor 402 can also include components such as a housing, gears, controlcircuitry, and the like. The rotary base 108 can include a plurality ofapertures 404 aligned with the plurality of hollow columns 110. Thepiston assemblies 112 can include a piston body 406 and a top hatassembly 408. The top hat assembly 408 includes a cam contact member202. The piston body 406 can include a bottom 410 portion. The pistonbody 406 can include piston rings 412 disposed around the bottom 410.The plurality of hollow columns 110 can also include a channel 414.

As can be seen in FIG. 4, the channel 414 extends part of the way downthe hollow column 110 from the top. The channel 414 can allow for aninterface between the piston assembly 112, which is largely disposedwithin the hollow column, and the cam track 306, which is outside thehollow column.

Referring now to FIG. 5, the apparatus for filling containers includes acam track 306. The apparatus for filling containers 102 can include acam track actuator 502. The cam track 306 can define a particularvertical profile. The vertical profile of the cam track 306 can definehow the piston assemblies 112 move up and down within the hollow columns110 as the rotary turret assembly 106 rotates. As such, the verticalprofile of the cam track 306 can dictate the amount of the food materialthat is drawn into the hollow columns 110 and then later dispensed asthe rotary turret assembly 106 rotates.

Referring now to FIG. 6, a side view the cam track 306 is shown. The camtrack 306 can include a top bar 307 and a lower bar 309. In someembodiments, the cam track 306 could include only the top bar or thebottom bar. The profile of the cam track 306 includes a first risingportion 602, a second rising portion 604, a first declining portion 606,a first flat portion 608, and a second declining portion 610. The firstrising portion can correspond to a filling phase. The second risingportion can correspond to an overfilling phase. The first decliningportion can correspond to a purging phase. The first flat portion cancorrespond to a hold phase. The second declining portion can correspondto a dispensing phase. Further aspects of these phases are described ingreater detail below.

The apparatus for filling containers 102 can also include one or morecam track actuators 502. The cam track actuator 502 can be a linearactuator or another type of actuator. The actuator can operateelectrically, hydraulically, magnetically, mechanically, or can operatebased on a combination thereof. The cam track actuator 502 can be usedto raise or lower the cam track 306, or a portion thereof, with respectto the rotary turret assembly 106. As such, the cam track actuator 502can be used to change the volumes of food material that are drawn upinto the hollow columns as might be periodically necessary, such as whenthe apparatus is reconfigured to fill containers of a different size.

Referring now to FIG. 7, the rotary turret assembly 106 includes arotary base 108 and a plurality of hollow columns 110. The pistonassemblies 112 include a cam contact member 202, and a cam track 306.The cam contact member 202 can include a cam roller 204. The cam roller204 can roll against the cam track 306 as it passes there over. However,in other embodiments, the cam contact member 202 could take on otherforms such as a cam slider or other type of track follower.

Referring now to FIG. 8, the cam track 306 includes a first risingportion 602, a second rising portion 604, a first declining portion 606,a first flat portion 608 and a second declining portion 610. Asdescribed above, the first rising portion can correspond to a fillingphase. The second rising portion can correspond to an overfilling phase.The first declining portion can correspond to a purging phase. The firstflat portion can correspond to a hold phase. The second decliningportion can correspond to a dispensing phase.

In some embodiments, the first rising portion wherein vertical distancecovered by the first rising portion is the same as the vertical distancecovered by the second declining portion. In some embodiments, thevertical distance covered by the first rising portion is at least about0.25 inches. In some embodiments, the vertical distance covered by thefirst rising portion is less than 18 inches. In some embodiments, thevertical distance covered by the first rising portion is from about 0.25inches to about 12 inches. In some embodiments, the second risingportion wherein vertical distance covered by the second rising portionis the same as the vertical distance covered by the first decliningportion. In some embodiments, the vertical distance covered by thesecond rising portion is at least about 0.5 inches, at least about 1.0inches, at least about 1.5 inches, at least about 2.0 inches, at leastabout 2.5 inches, at least about 3.0 inches, or at least about 4.0inches.

In some embodiments, the horizontal distance covered by the first flatportion is about 5 to about 95 percent of the horizontal distancecovered by the first rising portion and the second rising portioncombined. In some embodiments, the horizontal distance covered by thefirst flat portion is about 20 to about 80 percent of the horizontaldistance covered by the first rising portion and the second risingportion combined. In some embodiments, the horizontal distance coveredby the first flat portion is about 30 to 50 percent of the horizontaldistance covered by the first rising portion and the second risingportion combined.

In some embodiments, the vertical distance covered by the firstdeclining portion is equal to at least about 1% of the vertical distancecovered by the second declining portion. In some embodiments, thevertical distance covered by the first declining portion is equal to atleast about 5% of the vertical distance covered by the second decliningportion. In some embodiments, the vertical distance covered by the firstdeclining portion is equal to at least about 10% of the verticaldistance covered by the second declining portion. In some embodiments,the vertical distance covered by the first declining portion is equal toat least about 20% of the vertical distance covered by the seconddeclining portion. In some embodiments, the vertical distance covered bythe first declining portion is equal to at least about 50% of thevertical distance covered by the second declining portion. In someembodiments, the vertical distance covered by the first decliningportion is equal to at least about 100% of the vertical distance coveredby the second declining portion. In some embodiments, the verticaldistance covered by the first declining portion is equal to at leastabout 150% of the vertical distance covered by the second decliningportion. In some embodiments, the vertical distance covered by the firstdeclining portion is greater than the vertical distance covered by thesecond declining portion.

In some embodiments, the first rising portion and the second risingportion together cause the piston to move up in the plurality of hollowcolumns such that a volume of about 50 ml to about 3000 ml of a liquidfood material is drawn into a bottom portion of the plurality of hollowcolumns. In some embodiments, the first rising portion and the secondrising portion together cause the piston to move up in the plurality ofhollow columns such that a volume of about 300 ml to about 1000 ml of aliquid food material is drawn into a bottom portion of the plurality ofhollow columns.

In some embodiments, the slope of the first rising portion is greaterthan the absolute value of the slope of the second declining portion. Assuch, in some embodiments, the rate of drawing food product into thehollow columns can be faster than the rate of dispensing the foodproduct out of the hollow columns into containers. In some embodiments,the slope of the first rising portion can be the same as, or differentfrom, the slope of the second rising portion. In some embodiments, theslope of the first declining portion can be the same as, or differentfrom, the slope of the second declining portion.

Referring now to FIG. 9, the piston assemblies 112 include a cam contactmember 202. The cam contact member 202 can include a cam roller 204. Thepiston body 406 includes a top 902. The top hat assembly 408 includes acam contact member 202 and a release lever 206. The piston body 406 caninclude a bottom 410. The piston body 406 can include piston rings 412.The piston assemblies 112 can include a shaft 904.

The top hat assembly 408 can separate from the piston body 406. Inparticular, actuating the release lever 206 can allow the top hatassembly 408 to release from the piston body 406. Referring now to FIG.10, a view is shown of the top hat assembly 408 released from the pistonbody 406. It will be appreciated however that the release of the top hatassembly 408 from the piston body 406 can be triggered in various ways.By way of example, in some embodiments, the release of the top hatassembly 408 can be triggered pneumatically, such as with a shaft thatextends under pneumatic force to hit a lever or trigger on the top hatassembly. In some embodiments, the release of the top hat assembly 408can be triggered using coil gun technology, such as with a shaft thatextends using force provided by a coil gun in order to hit a lever ortrigger on the top hat assembly.

Referring now to FIG. 11, a cross-sectional schematic view of a portionof a piston assembly in accordance with various embodiments herein isshown. The piston assemblies 112 include a cam contact member 202. Thecam contact member 202 can include a cam roller 204. The piston body 406includes a top 902. The top hat assembly 408 includes a cam contactmember 202 and a release lever 206. The piston assemblies 112 caninclude a shaft 904.

Referring now to FIG. 12, the apparatus for filling containers 102 caninclude a container conveyor system 120. The container conveyor system120 can include an infeed timing screw 122 and a discharge timing screw124. The container conveyor system 120 can also include a containerelevation system 1302. The container elevation system 1302 can include acontainer rail 1202. The container conveyor system 120 can include areversing wheel 1204 and a container guide 1206.

Referring now to FIG. 13, the apparatus for filling containers 102 caninclude a container conveyor system 120. The apparatus for fillingcontainers 102 can include an infeed timing screw 122 and a dischargetiming screw 124. The container elevation system 1302 includes a railbrace 1304 and one or more brace actuators 1306. In addition, the braceactuator 1306 can be operatively connected to the rail brace 1304 suchthat the brace actuator 1306 can cause vertical movement of the railbrace 1304. The brace actuator 1306 can be a linear actuator or anothertype of actuator. The actuator can operate electrically, hydraulically,magnetically, mechanically, or can operate based on a combinationthereof. The container elevation system 1302 can also include acontainer rail 1202 (or track or belt). The container conveyor system120 can also include a reversing wheel 1204 and one or more containerguide 1206. The reversing wheel 1204 can be used to change the directionof movement of the containers. The container guide 1206 can be used toaid in keeping the containers on the container rail 1202.

Referring now to FIG. 14, the container elevation system 1302 includes arail brace 1304 and a brace actuator 1306. As described previously, therail brace 1304 can be disposed under or adjacent to the container rail1202. The rail brace 1304 can be operatively connected to at least aportion of the container rail 1202 such that vertical movement of therail brace 1304 causes vertical movement of at least a portion of thecontainer rail 1202. In some embodiments, the rail brace 1304 is onlyconnected to a portion of the container rail 1202 such that verticalmovement of the rail brace 1304 causes vertical movement of only aportion of the container rail 1202. In some embodiments, the rail brace1304 can form an S curve 1402. However, it will be appreciated that therail brace 1304 can also be formed into different shapes. In someembodiments, the rail brace can be formed of a material that resistscorrosion. In some embodiments, the rail brace can be formed ofstainless steel.

FIG. 15 shows a schematic view of elements of a fluid supply group inaccordance with various embodiments herein and illustrates a basic flowcircuit in accordance with various embodiments herein. The fluid supplygroup 114 includes a liquid supply tank 116 and a supply conduit 118.Food material can be put into the liquid supply tank 116 to replenishsupplies as the food material is placed into containers by theapparatus. The food materials then flow out of the supply tank 116 andthrough the supply conduit 118. The supply conduit 118 delivers the foodmaterials to a filler plenum assembly 302 that includes a plenum 304.Some of the food material will then be drawn into the hollow columns ofthe rotary turret assembly (not shown in this view). However, a portionof the food material in the plenum assembly 302 will pass out through aplenum outlet and pass through a plenum return conduit 314 to a pump312. Also, a portion of food material that is not put into containerscan be reclaimed in a reclaim trough 308 and then pass through a reclaimconduit 310 before returning to the pump 312. The pump 312 can then pushthe food material through a pumped return conduit 314 and directly orindirectly back to the supply tank 116.

Referring now to FIG. 16, the filler plenum assembly 302 includes aplenum 304. The fluid supply group 114 includes a liquid supply tank 116and a supply conduit 118. The apparatus for filling containers 102 caninclude a liner 1602. Aspects of the liner 1602 are provided in greaterdetail below. The fluid supply group 114 can include a reclaim trough308. The fluid supply group 114 can include a reclaim conduit 310. Thefluid supply group 114 can include a pump 312. The fluid supply group114 can include a plenum return conduit 314. The fluid supply group 114can include a pumped return conduit 316. The liquid supply tank 116 caninclude a hopper 1604.

Referring now to FIG. 17, the filler plenum assembly 302 includes aplenum 304. The fluid supply group 114 includes a liquid supply tank 116and a supply conduit 118. The apparatus for filling containers 102 caninclude a liner 1602. The fluid supply group 114 can include a reclaimtrough 308. The fluid supply group 114 can include a reclaim conduit310. The fluid supply group 114 can include a pump 312. The fluid supplygroup 114 can include a plenum return conduit 314. The fluid supplygroup 114 can include a pumped return conduit 316. The liquid supplytank 116 can include a hopper 1604. In some embodiments, the volumesensor 1902 can include a load cell 1702. However, other types of volumesensors can also be used.

Referring now to FIG. 18, the filler plenum assembly 302 includes aplenum 304. The apparatus for filling containers 102 can include a liner1602. The apparatus for filling containers 102 can include a gasket1802. The fluid supply group 114 can include a reclaim trough 308. Theplenum 304 can include a plenum outlet 1804. The plenum 304 can includea bottom surface 1806.

Referring now to FIG. 19, the filler plenum assembly 302 includes aplenum 304. The fluid supply group 114 includes a liquid supply tank 116and a supply conduit 118. The fluid supply group 114 can include areclaim trough 308. The fluid supply group 114 can include a reclaimconduit 310. The fluid supply group 114 can include a pump 312. Thefluid supply group 114 can include a plenum return conduit 314. Thefluid supply group 114 can include pumped a return conduit 316. Theliquid supply tank 116 can include volume sensor 1902.

The apparatus for filling containers can include a motor. The motor canbe operably connected to the rotary turret assembly. The rotary turretassembly can be rotated at a rotational speed of about 0.5 RPM to about25 RPM. In some embodiments, the rotary turret assembly can be rotatedat a rotational speed 10 RPM to about 20 RPM.

In some embodiments, the cam contact member can include a cam roller. Inother embodiments, the cam contact member can include a cam slider. Itwill be appreciated that various other elements could be used for thecontact member.

The rotary base can include a plurality of apertures aligned with theplurality of hollow columns. In some embodiments, the plurality ofhollow columns are removable from the rotary base. In some embodiments,the plurality of hollow columns are press fit into the apertures in therotary base. In some embodiments, the plurality of hollow columns arebolted onto the rotary base. In some embodiments, there can be fromabout 10 to about 120 hollow columns. In some embodiments, there can beabout 24 to 84 hollow columns. In some embodiments, there can be about30 to 42 hollow columns. In some embodiments, there are 36 hollowcolumns. In some embodiments, there are about 45 hollow columns. In someembodiments, there can be about 40 to 70 hollow columns.

It will be appreciated that the rotary base can be of different sizesdepending factors such as the desired capacity and speed of theapparatus. In some embodiments, the rotary base can have a diameter ofabout 36 inches to 108 inches. In some embodiments, the rotary base canhave a diameter of about 36 inches to 72 inches. In some embodiments,the rotary base can have a diameter of about 48 inches to 60 inches.

In some embodiments, the apparatus can accommodate the filling of 60containers per minute or more, 100 containers per minute or more, 200containers per minute or more, 300 containers per minute or more, 500containers per minute or more, 700 containers per minute or more, 900containers per minute or more, 1200 containers per minute or more, or1500 containers per minute or more. Pumps used herein can have acapacity sufficient to accommodate the desired filling capacities.

The apparatus for filling containers can include a liner. The liner canbe disposed between the plenum and the rotary base. The liner can haveproperties that are ideal for creating a seal between the bottom of therotary base and the plenum. In some embodiments, the liner is somewhatflexible and can deform slightly under pressure. In some embodiments,the liner can undergo plastic deformation and then return to itsoriginal shape. Liners can be made from various materials includingvarious metals (or alloys thereof), composites, ceramics, polymers andthe like. In some embodiments, the liner can be formed of a high densitypolymer. In some embodiments, the liner can include X-ray detectablematerial, such as a barium containing material or the like.

The apparatus for filling containers can include a gasket. The gasketcan be disposed between the plenum and the liner. In various embodimentsthe gasket can be deformable under pressure and can include a polymericmaterial. In some embodiments, the gasket can include an elastomericpolymer.

The piston assemblies can include a piston body. The piston body can bemade from a material that resists corrosion such as, but not limited to,various metals or alloys, polymers, composites, ceramics, or the like.

The piston body can include a bottom. The piston body can include one ormore piston rings. The piston rings can be disposed around the pistonbody adjacent the bottom. The piston rings can aid in creating a sealbetween the bottom of the piston body and the inner diameter of thehollow columns. The piston rings can be made of various materials. Insome embodiments, the piston rings can include a polymer. In someembodiments, the piston rings can include X-ray detectable material. Insome embodiments, the piston body can have an outer diameter of about 1inch to about 4 inches at its widest point. In some embodiments, thepiston body can have an outer diameter of about 2 inches to about 3inches at its widest point. In some embodiments, the piston body canhave an outer diameter of about 2.375 inches at its widest point.

The plurality of hollow columns can include a channel. The channel canextend from the top of the hollow columns downward to a point on thehollow columns. In some embodiments, the channel can extend downward toa vertical point on or near the middle of the hollow columns. The pistonassemblies can include a shaft. The shaft can connect the cam contactmember and the top hat assembly. The shaft can provide a connectionbetween the top hat assembly of the piston assemblies and the camcontact member. Specifically, the shaft can move up and down within thechannel in the hollow columns.

The apparatus for filling containers can include an infeed timing screwand a discharge timing screw. The timing screws can have various pitchesdepending on the size of containers to be used and the desired spacingin between containers.

The container elevation system can include a container rail (or track orbelt). Containers can move along the container rail. In variousembodiments, the container rail can be disposed over the rail brace. Insome embodiments, the brace actuator can move the rail brace andtherefore can move at least a portion of the container rail. In someembodiments, the brace actuator can move the rail brace up to 6 inchesvertically. In some embodiments, the brace actuator can move the railbrace up to 4 inches vertically. In various embodiments, movement of thebrace actuator does not change the height of the infeed timing screw orthe discharge timing screw. In various embodiments, movement of thebrace actuator does not change the height of the reversing wheel.

In various embodiments, the apparatus for filling containers includes afluid supply group. The fluid supply group can include a liquid supplytank, a supply conduit, a reclaim trough, a reclaim conduit, a plenumassembly, a plenum return conduit, a pump, and a pumped return conduit.Conduits used herein can be made of various materials (including, butnot limited to, polymers, metals and the like) and have variousdiameters and lengths. It will be appreciated that the fluid supplygroup can also include other components such as valves, flow sensors,control interfaces and the like.

The supply conduit can provide fluid communication between the liquidsupply tank and the plenum. The reclaim conduit can provide fluidcommunication between the reclaim trough and the pump. The plenum returnconduit can provide fluid communication between the plenum outlet andthe pump. The pumped return conduit can provide fluid communicationbetween the pump and the liquid supply tank. It will also be appreciatedthat to the extent that it is described that food materials can beconveyed from one component to another (or that one component is influid communication with another), that such conveyance or communicationcan either be direct or indirect in it is possible to include othercomponents in between such as additional conduits, valves, and the like.

The fluid supply group can include a pump. The pump can be of varioustypes. In some embodiments, can be a peristaltic type pump. In variousembodiments, the pump can be electrically driven. In some embodimentsthe pump can be pneumatically or hydraulically driven. In someembodiments, the apparatus can include more than one pump. In someembodiments, the fluid supply group can include more than one pump. Insome embodiments, the apparatus can include a pump as part of somethingother than the fluid supply group.

In some embodiments, the liquid supply tank can have a volume of about 5gallons to about 500 gallons. In some embodiments, the liquid supplytank can have a volume of about 25 gallons to about 200 gallons. Theliquid supply tank can include a hopper. In some embodiments, the liquidsupply tank can include a volume sensor. It will be appreciated thatvolume can be sensed in various ways and thus many different types ofvolume sensors can be used. In some embodiments, the volume sensor caninclude a load cell.

The plenum can include a plenum outlet. The plenum can include a bottomsurface. The bottom surface can be sloped downwardly to the plenumoutlet.

It will be appreciated that while not shown herein, the rotary fillingapparatus of various embodiments can include a control module including,but not limited to, control circuitry that can be used to executeoperations of methods herein as well as control operational aspects ofthe apparatus including, but not limited to, operation of the actuators,motors, and pumps of the apparatus.

Methods

It will be appreciated that embodiments herein can include variousmethods. In an embodiment, the invention includes a method for fillingcontainers. The method for filling containers can include rotating arotary turret assembly, the rotary turret assembly comprising a rotarybase and a plurality of hollow columns mounted on the rotary base andarranged in a circle. The method can include contacting a cam contactmember against a cam track to cause the piston assemblies disposedwithin the hollow columns to move up and down. The method can furtherinclude drawing a food material into a bottom portion of the hollowcolumns when the piston assemblies move up and dispensing the foodmaterial into a container when the piston assemblies move down. Themethod for filling containers can include drawing the food materialupward from a plenum.

In various embodiments of the method, the amount of the food materialdrawn into the hollow column exceeds the amount dispenses into thecontainer. By way of example, the method for filling containers caninclude purging a portion of the food material when the pistonassemblies move down prior to dispensing the food material into thecontainer. The method for filling containers can include a purging thefood material downward into a plenum. The method for filling containerscan include holding the food material in the bottom of the hollow columnafter purging a portion of the food material and before dispensing thefood material.

While not intending to be bound by theory, it is believed thatoverfilling the hollow columns followed by purging a portion prior tofilling of the containers results in in enhanced consistency in terms ofboth the total amount of product that is filled into containers as wellas the relative amounts of the liquid portion of the food productcompared to the particulate portions of the food product (when the foodproduct includes particulate materials).

Referring now to FIG. 20, the method for filling containers 2002includes rotating a rotary turret assembly, the rotary turret assemblycomprising a rotary base and a plurality of hollow columns mounted onthe rotary base and arranged in a circle 2004, contacting a cam contactmember against a cam track to cause piston assemblies disposed withinthe hollow columns to move up and down 2006, drawing a food materialinto a bottom portion of the hollow columns when the piston assembliesmove up 2008, and dispensing the food material into a container when thepiston assemblies move down 2010.

It will be appreciated that there may be occasions in which a containeris missing from the sequence of containers being fed into the rotaryturret assembly. In various embodiments, methods are included thatprovide for a way of not filling the hollow column with a food materialwhen there is not a container to be filled in alignment with theparticular hollow column of the rotary turret assembly.

In an embodiment, the invention includes a method for filling containersincluding rotating a rotary turret assembly. The method for fillingcontainers can include detecting whether a container to be filled isaligned with a particular hollow column and engaging a release leverthat allows a top hat assembly to release from a piston body assembly ifa container is not detected. The method can further include contacting acam contact member operably connected to the top hat assembly against acam track to cause the top hat assembly disposed within the hollowcolumns to move up and down. The method can further include drawing afood material into a bottom portion of the hollow columns when thepiston body assemblies move up if the top hat assembly is not releasedfrom the piston body assembly and dispensing the food material into acontainer when the piston body assemblies move down if the top hatassembly is not released from the piston body assembly.

Referring now to FIG. 21, the method for filling containers 2102includes rotating a rotary turret assembly, the rotary turret assemblycomprising a rotary base and a plurality of hollow columns mounted onthe rotary base and arranged in a circle 2104, detecting whether acontainer to be filled is aligned with a particular hollow column 2106,engaging a release lever that allows a top hat assembly to release froma piston body assembly if a container is not detected, the top hatassembly and the piston body assembly disposed in the hollow columns2108, contacting a cam contact member operably connected to the top hatassembly against a cam track to cause the top hat assembly disposedwithin the hollow columns to move up and down 2110, drawing a foodmaterial into a bottom portion of the hollow columns when the pistonbody assemblies move up if the top hat assembly is not released from thepiston body assembly 2112, and dispensing the food material into acontainer when the piston body assemblies move down if the top hatassembly is not released from the piston body assembly 2114.

It will be appreciated that it is useful to be able to reconfigure theapparatus for filling containers so as to accommodate various sizecontainers. In particular, different size containers may have differentheights. However, it can be difficult to adjust the height ofparticularly large pieces of equipment such as the rotary turretassembly. As such, in various embodiments herein, a rail upon which thecontainers travel can be moved vertically up and down so that the top ofthe containers matches the appropriate height for the rotary turretassembly without the need to adjust the height of the rotary turretassembly.

In an embodiment, the invention includes a method for fillingcontainers. The method for filling containers can include rotating arotary turret assembly, the rotary turret assembly comprising a rotarybase and a plurality of hollow columns mounted on the rotary base andarranged in a circle, feeding containers to be filled into an infeedtiming screw, passing the containers over a container rail, wherein thecontainer rail is disposed adjacent the infeed timing screw, adjustingthe height of the containers and container rail relative to the rotaryturret.

Referring now to FIG. 22, the method for filling containers 2202includes rotating a rotary turret assembly, the rotary turret assemblycomprising a rotary base and a plurality of hollow columns mounted onthe rotary base and arranged in a circle 2204, feeding containers to befilled into an infeed timing screw 2206, passing the containers over acontainer rail, wherein the container rail is disposed adjacent theinfeed timing screw 2208, adjusting the height of the containers andcontainer rail relative to the rotary turret and the infeed timing screw2210.

While not intending to be bound by theory, it is believed that there areadvantages associated with recirculating food material in a closed loopsystem. In addition, it will be appreciated that a need may arise fromtime to time to temporarily stop the filling operation. If food materialis stagnant during these temporary stoppages, there may be a need topurge all food material in the apparatus before restarting the fillingoperation due to aspects which may occur such as settling of componentsof the food material which may result in reduced consistency or even, insome cases, a degrees of phase separation of different components withinthe food material. In various embodiments herein, the food material canbe recirculated so as to maintain the food material in a condition forfilling of containers.

In an embodiment, the invention includes a method for filling containersincluding delivering a food product to a plenum disposed under a portionof the rotary turret assembly by conveying the food product from aliquid supply tank through a supply conduit to the plenum. The methodcan further include drawing a first portion of the food product from theplenum into the hollow columns for dispensing into containers to befilled. The method can further include collecting a second portion ofthe food product disposed in the plenum and conveying the collected foodproduct through an outlet in the plenum and to a pump. The method canfurther include conveying the collected food product from the pump backto the liquid supply tank.

In some embodiments, the method for filling containers can also includecollecting a third portion of the food product in a reclaim troughdisposed adjacent the plenum. The method for filling containers caninclude conveying the collected third portion to the pump.

In some embodiments, the method can include continuing to collect thesecond portion of the food product and conveying the collected foodproduct from the pump back to the liquid supply tank even when the stepof drawing a first portion of the food product from the plenum into thehollow columns for dispensing into containers to be filled istemporarily ceased.

Referring now to FIG. 23, the method for filling containers 2302includes rotating a rotary turret assembly, the rotary turret assemblycomprising a rotary base and a plurality of hollow columns mounted onthe rotary base and arranged in a circle 2304, delivering a food productto a plenum disposed under a portion of the rotary turret assembly byconveying the food product from a liquid supply tank through a supplyconduit to the plenum 2306, drawing a first portion of the food productfrom the plenum into the hollow columns for dispensing into containersto be filled 2308, collecting a second portion of the food productdisposed in the plenum and conveying the collected food product throughan outlet in the plenum and to a pump 2310, and conveying the collectedfood product from the pump back to the liquid supply tank 2312. Themethod for filling containers 2302 can include collecting a thirdportion of the food product in a reclaim trough disposed adjacent theplenum 2314. The method for filling containers 2302 can includeconveying the collected third portion to the pump 2316.

It should be noted that, as used in this specification and the appendedclaims, the singular forms ‘a,’ ‘an,’ and ‘the’ include plural referentsunless the content clearly dictates otherwise. Thus, for example,reference to a composition containing ‘a compound’ includes a mixture oftwo or more compounds. It should also be noted that the term ‘or’ isgenerally employed in its sense including ‘and/or’ unless the contentclearly dictates otherwise.

It should also be noted that, as used in this specification and theappended claims, the phrase ‘configured’ describes a system, apparatus,or other structure that is constructed or configured to perform aparticular task or adopt a particular configuration to. The phrase‘configured’ can be used interchangeably with other similar phrases suchas arranged and configured, constructed and arranged, constructed,manufactured and arranged, and the like.

All publications and patent applications in this specification areindicative of the level of ordinary skill in the art to which thisinvention pertains. All publications and patent applications are hereinincorporated by reference to the same extent as if each individualpublication or patent application was specifically and individuallyindicated by reference.

The invention has been described with reference to various specific andpreferred embodiments and techniques. However, it should be understoodthat many variations and modifications may be made while remainingwithin the spirit and scope of the invention.

1-33. (canceled)
 34. An apparatus for filling containers comprising: afiller frame; a rotary turret assembly rotatably coupled to the fillerframe, the rotary turret assembly comprising a rotary base and aplurality of hollow columns mounted on the rotary base and arranged in acircle; a filler plenum assembly underlying a portion of the rotaryturret assembly, the filler plenum assembly comprising a plenum, whereinthe plenum is in fluid communication with the hollow columns for aportion of each rotation of the rotary turret assembly; a plurality ofpiston assemblies disposed in the hollow columns, the piston assembliesconfigured to move up and down within the hollow columns, wherein eachpiston assembly comprises a piston body having a top and a top hatassembly configured to releasably engage the top of the piston body,each top hat assembly comprising a cam contact member; a release lever,wherein the piston body and the top hat assembly can release from oneanother when the release lever is engaged; a lever actuator configuredto contact the release lever when a container to be filled is absent; acam track operably connected to the filler frame; wherein rotation ofthe rotary column group causes the cam contact members of the pistonassemblies to move over a surface of the cam track causing verticalmovement of the top hat assemblies of the piston assemblies relative tothe hollow columns they are disposed in; and a fluid supply group influid communication with the plenum, the fluid supply group comprising aliquid supply tank, and a supply conduit providing fluid communicationbetween the liquid supply tank and the plenum.
 35. The apparatus forfilling containers of claim 34, the piston body further comprising abottom and piston rings disposed around the piston body adjacent thebottom, the piston rings comprising an X-ray detectable material. 36.The apparatus for filling containers of claim 34, the piston body havingan outer diameter of about 1 inch to about 4 inches at its widest point.37. The apparatus for filling containers of claim 34, the piston bodyhaving an outer diameter of about 2 inches to about 3 inches at itswidest point.
 38. The apparatus for filling containers of claim 34, thehollow columns comprising a channel extending from the top of the hollowcolumns to a vertical mid-point on the hollow columns.
 39. The apparatusfor filling containers of claim 34, the piston assembly furthercomprising a shaft connecting the cam contact member and the top hatassembly. 40-62. (canceled)
 63. The apparatus for filling containers ofclaim 34, the cam track comprising a cam track surface, the cam tracksurface comprising a first rising portion corresponding to a fillingphase, a second rising portion corresponding to an overfilling phase; afirst declining portion corresponding to a purging phase; a first flatportion corresponding to a hold phase; and a second declining portioncorresponding to a dispensing phase.
 64. The apparatus for fillingcontainers of claim 63, wherein the vertical distance covered by thefirst rising portion is the same as the second declining portion. 65.The apparatus for filling containers of claim 63, wherein the verticaldistance covered by the first rising portion is at least about 0.25inches.
 66. The apparatus for filling containers of claim 63, whereinthe vertical distance covered by the second rising portion is the sameas the first declining portion.
 67. The apparatus for filling containersof claim 63, wherein the vertical distance covered by the second risingportion is at least about 0.25 inches.
 68. The apparatus for fillingcontainers of claim 63, wherein the horizontal distance covered by thefirst flat portion is about 20 to 60 percent of the horizontal distancecovered by the first rising portion and the second rising portioncombined.
 69. The apparatus for filling containers of claim 63, whereinthe horizontal distance covered by the first flat portion is about 30 to50 percent of the horizontal distance covered by the first risingportion and the second rising portion combined.
 70. The apparatus forfilling containers of claim 63, wherein the vertical distance covered bythe first declining portion is equal to at least about 5% of thevertical distance covered by the second declining portion.
 71. Theapparatus for filling containers of claim 63, wherein the verticaldistance covered by the first declining portion is equal to at leastabout 10% of the vertical distance covered by the second decliningportion.
 72. The apparatus for filling containers of claim 63, whereinthe first rising portion and the second rising portion together causethe piston to move up in the hollow column such that a volume of about50 ml to about 3000 ml of a liquid food material is drawn into a bottomportion of the hollow column.
 73. The apparatus for filling containersof claim 63, wherein the first rising portion and the second risingportion together cause the piston to move up in the hollow column suchthat a volume of about 50 ml to about 1500 ml of a liquid food materialis drawn into a bottom portion of the hollow column.
 74. The apparatusfor filling containers of claim 63, wherein the first rising portion andthe second rising portion together cause the piston to move up in thehollow column such that a volume of about 300 ml to about 1000 ml of aliquid food material is drawn into a bottom portion of the hollowcolumn.
 75. The apparatus for filling containers of claim 63, whereinthe slope of the first rising portion is greater than the absolute valueof the slope of the second declining portion.
 76. The apparatus forfilling containers of claim 63, the cam contact member comprising a camroller.